A Review on Food Extrusion Technology: A Versatile Processing Method for Innovative Product Development

Abstract

Food extrusion is a versatile food processing technology that can transform a variety of raw materials into products with desirable textural, structural, nutritional, and functional characteristics. This review examines the principles, mechanisms, types, and technological advances in food extrusion, highlighting its role in nutritional improvement, sustainable processing, and the development of innovative food products.  Extrusion processing integrates mixing, cooking, shearing, texturization, and shaping into a single continuous operation, offering broad potential for the development of innovative food products. Despite its relatively short processing time, the combined influence of heat, moisture, pressure, and shear induces critical physicochemical transformations in food components, including starch gelatinization, protein denaturation and restructuring, hydration, lipid melting, plasticization, and expansion. These modifications govern the quality, functionality, and sensory attributes of the final products. The capacity to utilise cereals, millets, legumes, tubers, fruits, vegetables, and agro-industrial by-products further extends the scope of extrusion, enabling value addition, nutritional enhancement, and efficient resource utilisation in modern food systems. Food extrusion brings together efficiency, versatility, and innovation to deliver nutritionally enriched, shelf-stable products with tailored textures, flavours, and nutrient profiles. With ongoing technological advancements, it addresses food security and environmental challenges, meets the demand for healthy, convenient, and customised foods, and serves as a gateway to next-generation innovative food solutions.